Roll-up surface, system and method for wet environments

ABSTRACT

The present invention provides a ground flooring device, system and method which provides heretofore unknown strength, versatility, lightness of weight, durability, portability, storability and liquid management capabilities. The invention includes connectable slats or panels having connection means which allow a series of slats to be quickly assembled, rolled up for storage or transport, and unrolled for deployment. The slats can be secured in a series, and a series of slats can be secured in multiple rows to create a solid, manipulable floor readily deployable on ground areas of virtually any shape and wetness characteristics.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit, pursuant to 35 U.S.C. §119(e), of applicant's provisional U.S. patent application Ser. No. 60/651,382 filed Feb. 9, 2005, entitled “Roll-Up Surface, System and Method for Wet Environments”, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to roll-up material surfaces such as portable ground flooring systems, and methods of installing and using the same.

BACKGROUND

Unmodified ground surfaces hinder the ability to set up quick, stable, level and secure environments for a variety of purposes. For example, outdoor field events such as carnivals, corporate outings, wine tastings, mountain bike races and even military deployments often require booths, tents or other structures with solid and stable flooring from which to manage the event. Wet environments such as might be found in the above illustrative cases or in/around hospital settings, for example, also present particular challenges in providing a secure, stable surface which keeps water and other liquids from collecting and interfering with people and equipment moving atop the surface. In a decontamination deployment, for example, where jets spout fluid towards individuals within a contained environment for decontamination, it is imperative that the floor surface be kept free of collecting water and liquids so as to minimize the risk of re-exposure and other dangers associated with decontamination.

Past efforts attempting to address the above and related challenges have erred in being too heavy, too light, too stiff, too unmanageable and/or otherwise incapable of providing a rapidly deployable, stable surface which helps prevent the collection of water, waste water, and other liquids on the surface. What is needed is a lightweight, durable, readily portable flooring system that keeps liquid substances from collecting on the surface and can be quickly deployed in an otherwise unmodified environment. What is further needed is a flooring system that minimizes necessary storage space when not in use or when being transported, while also maintaining sufficient strength overall. What is further needed is a flooring system that can be adapted to various shapes of ground surfaces and wet environments, including uneven ground.

SUMMARY OF THE PRESENT INVENTION

The present invention provides a ground flooring device, system and method which provides heretofore unknown strength, versatility, lightness of weight, durability, portability, storability and liquid management capabilities. The invention includes connectable slats or panels having connection means which allow a series of slats to be quickly assembled, rolled up for storage or transport, and unrolled for deployment. The slats can be secured in a series, and a series of slats can be secured in multiple rows to create a solid, manipulable floor readily deployable on ground areas of virtually any shape and wetness characteristics.

The present system can comprise multiple slats or panels secured edge-to-edge by specially adapted connector members provided on the edges of the panels for flexible, yet secure attachment. In one embodiment, each panel member is made of formed and extruded plastic material or other solid material suitable for the purposes of the present invention. The ground covering systems of the present invention can further have a variety of shapes when constructed, including rectangular, octagonal, circular or other geometric shape. For a given end shape, each panel member can be substantially uniform in size and shape. For example, for the development of a rectangular ground covering, each panel member can be rectangular, and for a circular ground covering, each panel member may be shaped like a piece of pie, such that when adjoined side-by-side with other panel members, a circular ground cover is developed.

The connector members allow the present invention to be securely maintained while also allowing flooring of all sizes to be rapidly rolled up for transport and re-deployment. By way of example, the present invention can be used as flooring for military applications, decontamination shelters, entertainment and sporting event applications, racing pit and staging area protection applications, landscaping and construction access protection and various other flooring uses. The present invention rolls up for fast set up or take down as well as for compact storage and transport. In one embodiment, the slats or panels can be formed of high-impact plastic which largely conforms to non-level, rolling ground while maintaining bridging strength for ground discontinuities.

BRIEF DESCRIPTON OF THE DRAWINGS

FIG. 1 is a right side view of one embodiment of a single panel as provided by the present invention.

FIG. 2A is a right side view of an embodiment of a single panel element of the present invention and FIG. 2B is an exploded view of a top surface member thereof.

FIG. 3 is a perspective view of one series of surface panels as provided by one embodiment of the present invention.

FIG. 4 is a front perspective view of an opened decontamination shelter which can be a potential environment where the present invention may be employed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a right side view of one embodiment of a single panel 10 in connection with the present invention. The panel 10 can comprise a unitary member of formed and/or extruded ABS plastic or similar material, which is provided with a set of top segments 12, a set of bottom segments 14 and side walls 16. As shown in FIGS. 1 and 3, the top segments 12 can comprise a full top surface generally as at 13, and the bottom segments 14 can comprise a full bottom surface generally as at 15. As shown in FIGS. 1, 2A and 2B, top segments 12 can, in one embodiment, be provided with non-slip ribbing on the outer surface thereof as at 18, which assists in providing traction to people or items which are moving about top surface 13. Side walls 16 connect respective edges of the set of top segments 12 and bottom segments 14, and side walls are substantially perpendicular to top and bottom segments for stability. The side walls 16 extend substantially the length of the slat. The side walls are also integrally formed with, extend from, and are generally perpendicular to the bottom 14 and top 12 segments.

Each top segment 12 will preferably have a greater width W than the width Y of bottom segment 14, as shown in FIG. 1. As such, the opening 20 created between each top segment 12 and the side walls 16 will be greater and will have a larger volume than the opening 22 created between each bottom segment 14 and the side walls 16. This dimensioning assists the invention in its ability to maintain flexibility and ease of roll up, while also providing a greater surface area for walking on the top surface 13 and further providing openings 20 of sufficient size for retaining or allowing pass-through of liquids. As such, the invention helps keep the top surface dry when deployed.

Slip joint or foot connector members 30, 32 associated with the present invention act to secure the panel members horizontally. In one embodiment, the connector members bring adjacent panels into a tight adjacent fit to give the semblance of a permanent seam. By way of example only and with reference to FIGS. 2A and 2B, elements of the present invention can be provided with approximate dimensions as shown in inches. In this embodiment, the top segments 12 can be thicker than bottom segments 14 for load strength. The thickness of top segment may be approximately the same as the thickness T of the top portion of the side wall 16, which then tapers as the side wall moves downward towards the bottom segment. By becoming thinner at the bottom, the side walls allow for greater flexibility of the invention when rolling. It will be appreciated that all of the dimensions shown can vary in order to accommodate different structural requirements, such as flexibility, stability, water or liquid height and other deployment environment considerations.

As described above and as shown in FIGS. 1, 2A and 2B, each panel member can have upper segments provided with appropriate ridges or ribbing 18. In one embodiment, these ridges extend substantially parallel to the corner edges 42 of the running members 17 and substantially for the length of the panel or slat member, as shown in FIG. 3. It will be appreciated that, while the length of the panel in FIG. 3 is relatively short, the present invention contemplates panel members having a length and/or width of anywhere from six inches to eighty inches. This range of lengths and/or widths can be exceeded up or down depending upon the particular application involved, and the invention is no less effective outside of this range. The ridges 18 provide for anti-skid surface resistance. This assists the stability and overall applicability of the present invention for deployments where there may be wet surfaces.

As shown in FIGS. 1 and 3, each panel or slat member 10 is provided with a first side foot or connector member (e.g., male slip joint) 30 and a second side foot or connector member (e.g., female slip joint) 32. These members can be provided with approximate dimensions as shown in FIG. 2A to assist in yielding a stable, strong attachment. In one embodiment, the panels are joined by aligning the edges of two panels and sliding the panels together so as to inter-connect their respective hinge members (see FIG. 3). In another embodiment, panels are joined by pushing or snapping the hinge members together. In this way, a first slat 10 a is connected to another slat 10 b. In one embodiment, this connection is continuous for the length of the side walls. In one embodiment of the invention, the connector members 30, 32 are integrally formed with and extend from respective lower portions 25 of the side walls 16 a, 16 b, as shown in FIG. 2A. Connector members permit relative rotation of each of the first and second slats about an axis (e.g. A in FIG. 3) substantially parallel to the side walls.

In the embodiment as shown in FIGS. 1 through 3, the connector members 30, 32 form a substantially inverted T-shape and T-shape receptacle, respectively, in side view and/or in cross section. The T-shape receptacle connector member 32 is formed by curved wall members 33 and 34 integrally formed with the panel, wherein the curved wall members bend back towards one another to form a T-shape receptacle or opening. As shown in FIG. 1, tips 36 of curved wall members can point towards one another so as to form tight fitting and strong support walls for the inverted T-shaped male foot member 30. It will be appreciated that other slidingly engageable or snappingly engageable members can be employed as connector members. For example, a “doll's head” spherical-type connector member may be connected to a connector member having a circular opening and neck portion whereby the “doll's head” can be snapped in place.

It will thus be seen that each slat 10 comprises a unitary rigid member having a first foot 30 and a second foot 32 lying in a foot plane B, as shown in FIG. 1. The slat extends from the first foot 30 to form one or more running members 17. Each running member 17 has a first side wall 16 c, which is then bent at an approximately right angle to the first running member first side wall and extends from the first running member first side wall to form a first running member top segment 12. The slat is then bent at an approximately right angle back towards the foot plane B so as to form a first running member second side wall 16 d. Each running member thus comprises a first side wall 16 c, a top segment 12 and a second side wall 16 d. The slat is then bent at an approximately right angle and extends further away from the first running member first and second side walls so as to form a bottom segment 14 substantially coplanar with the foot plane B. Each additional running member first side wall extends from such a bottom segment in a direction substantially perpendicular to the foot plane and substantially parallel with the first running member first side wall. The last running member has a bottom member which has a second foot 32 integrally formed therewith, such that this second foot can engage a first foot of an adjoining slat member. This permits relative rotation of each of the first and second slats about an axis A parallel to the side walls, as indicated by the arrows shown in FIG. 3.

A method of providing a flooring in accordance with the present invention can occur as follows. First, two or more slats are provided, wherein each slat has a first foot and a second foot lying in a foot plane, each slat further having a length and each slat comprising a unitary rigid member extending from a first foot to form a first running member. As described above, the first running member comprises a first side wall extending from the first foot in a direction substantially perpendicular to the foot plane, a top segment formed by bending the unitary rigid member at a substantially right angle to the first side wall so as to be substantially parallel to the foot plane, and a second side wall formed by bending the unitary rigid member back towards the foot plane at a substantially right angle. The unitary member (for each slat) is then bent at a substantially right angle from the second side wall so as to extend further away from the first and second side walls so as to form a bottom segment substantially coplanar with the foot plane. Next the unitary rigid member is further modified so as to include at least one additional running member extending from the bottom segment, wherein the additional running member has a first side wall, a top segment, and a second side wall similar to the first running member, and wherein the additional running member first side wall extends from the bottom segment in a direction substantially perpendicular to the foot plane and substantially parallel with the first running member first side wall. The additional running member bottom member has a second foot integrally formed therewith, such that this second foot of the first slat can engage a first foot of the second slat so as to permit relative rotation of each of the first and second slats about an axis parallel to the side walls.

It will be appreciated that the unitary member can be formed using injection molding techniques known in the art, wherein the mold is created using one or more slats or build ups of slats as shaped and formed above.

The panel members can be secured together as rows through the use of “hook” and “loop” type fasteners as well as VHB “very high bond” fastening systems as are generally known in the art. For example, loop strips can be secured to the bottom side of rows of panels using VHB material. The VHB material adheres to the bottom of the panels, such that approximately one-half of the width of the loop strip is secured to the bottom of one row of panels and the approximate other half of the width of the loop strip is secured to the bottom of the longitudinally adjacent row of panels. In one embodiment of the invention, strips are 1.5 inches in width. With the strip securely in place, the outwardly facing loop sections are available for mating with a larger “hook” strip, which can be wide enough (e.g., 4 inches in width) to secure to two loop strips on adjoining panel rows. In this way, the present invention allows the rows of panel members to be tightly secured.

The panel members can be secured end-to-end by solvent welding or heat staking separate panel members together and crimping the feet portions together. Solvent welding and heat staking techniques are generally known in the field, and can further be employed to secure separate panel members together side-by-side. Once panel members are so joined, it is difficult to then remove the bond and thereby separate the panels again. Such an attachment method may not be desirable in certain applications such as military deployments where the invention may be rapidly and frequently broken down and built back up. It will be appreciated that, in one embodiment of the invention, a panel member may be turned upside down so as to create a tight fitting, nested engagement with one or more additional panel members, wherein running members on the upside-down panel member cooperatively engage running members on the right side up panel(s). In this way, panel members can be securely joined side-to-side or end-to-end without solvent welding or heat staking, for example. Such a connection method can provide further support for adjacent panels joined through connector members 30, 32 or even in lieu of connector members 30, 32. In a further embodiment, a separate U-channel connector strip can be provided so as to engage cooperating and adjacent running members on two or more panels being joined.

The connector members 30, 32 can become engaged by sliding adjacent panel members together so as to interlock the connector members, or by snapping the connector members together with sufficient force to temporarily displace the connector members to allow room for the interlocking to take place. The slats or panels can be disconnected from one another using the reverse process.

In one embodiment of the invention, the present invention can be assembled and deployed as follows. First, a plurality of panels or slats are obtained and slidingly engaged or snappingly engaged edge to edge, for example, using opposing connector members. Alternatively or additionally, the panels can be joined by turning an additional panel member over such that its running members nestingly and securely engage cooperating running members on the panels being joined. As a further alternative, a U-channel connector strip can be provided so as to engage cooperating and adjacent running members on two or more panels being joined. Next, the series of slats can be provided with bonding elements, such as VHB material towards each outer, narrower end of each slat, and a loop strip attached to the VHB material so as to run the entire width of the assembled series on or near each end. The addition of VHB material and loop strips can occur on both the upper and the lower sides of the series of panels. Alternatively or additionally, the bonding elements can comprise solvent welding, heat staking and crimping, for example. Next, an adjoining row of similarly assembled panels can be aligned end-to-end with the first series of panels, and secured together using a wider “hook” strip on the bottom side of the panels as described above. The system of the present invention can allow a rectangular flooring to be constructed by aligning multiple panel or slat members edge to edge in parallel rows. While described in terms of a rectangular shape, it will be apparent from the disclosure herein that the present invention can be adapted to suit other shapes as desired, including without limitation circular, polygonal or other shape.

FIG. 4 shows a front perspective view of an opened decontamination shelter 60 which can be a potential environment where the present invention may be employed. The shelter 60 can include jet nozzles, sprayers, shower heads or the like 62 which spray water or a decontamination mixture onto individuals who may have been exposed to hazardous materials. Front 64, rear 65 and side 66 berms will typically be higher than the natural floor 67 in such shelters, and it is upon this floor 67 that the present invention can be placed. The flooring can be unrolled and then placed upon the floor, or the flooring can be placed adjacent the front 64 or rear 65 berm in the rolled up position, and then unrolled towards the berm at the other end. While such environments typically employ pumps at one or more ends to pump the collected water out of the shelter, the present invention allows individuals to stand atop a secure, relatively slip-free surface while experiencing the decontamination rinse, as opposed to sloshing around in inches of water which can collect in many typical shelter applications.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

What is claimed and desired to be secured by Letters Patent is:
 1. A flooring, comprising: a first and second slat, each slat having a first foot and a second foot lying in a foot plane, each slat further having a length and each slat comprising a unitary rigid member extending from a first foot to form a first running member, said first running member comprising: a first side wall extending from said first foot in a direction substantially perpendicular to said foot plane, a top segment formed by bending said unitary rigid member at a substantially right angle to said first side wall so as to be substantially parallel to said foot plane, and a second side wall formed by bending said unitary rigid member back towards said foot plane at a substantially right angle; said unitary member further being bent at a substantially right angle from said second side wall and extending further away from said first and second side walls so as to form a bottom segment substantially coplanar with said foot plane, said unitary rigid member extending at least one additional running member from said bottom segment, wherein said at least one additional running member has a first side wall, a top segment, and a second side wall, and wherein said at least one additional running member first side wall extends from said bottom segment in a direction substantially perpendicular to said foot plane and substantially parallel with said first running member first side wall, said at least one additional running member bottom member having a second foot integrally formed therewith, such that said second foot of said first slat can engage said first foot of said second slat so as to permit relative rotation of each of said first and second slats about an axis parallel to the side walls.
 2. The flooring of claim 1 wherein said top segments of said first runner member and said at least one additional runner member are wider than said bottom segment.
 3. The flooring of claim 1 wherein said first and second side walls of said first runner member and said at least one additional runner member each have a height H, wherein said top segments of said first runner member and said at least one additional runner member each have a width W, and wherein said height H is greater than said width W.
 4. The flooring of claim 1 wherein said first and second side wall members of said first runner member and said at least one additional runner member each have a thickness T, and wherein said thickness T tapers from a wide point nearest said top segment to a narrower point at a bottom of said side walls.
 5. The flooring of claim 1 wherein said first foot member extends substantially perpendicularly from said first side wall member in both directions.
 6. The flooring of claim 1 wherein said second foot member extends substantially perpendicularly from said at least one additional runner member second side wall in a single direction.
 7. The flooring of claim 1 wherein said second foot member terminates in a curved back segment forming an inverted T-shaped receptacle connector member.
 8. The flooring of claim 7 wherein said T-shape receptacle connector member is formed by a pair of curved wall members integrally formed with said at least one additional runner member, said curved wall members each having an upper end tip which extends towards the opposing curved wall member upper end tip.
 9. The flooring of claim 1 further including a U-channel connector for cooperatively engaging at least one running member from said first slat and at least one running member from said second slat so as to securely join said first and second slats in end-to-end relation.
 10. The flooring of claim 1 further including a third slat secured in side-by-side relation to at least one of said first or said second slat, said third slat having a plurality of running members which cooperatively engage at least one running member of said first slat or said second slat.
 11. A method of providing a roll-up surface, comprising the steps of: providing a first and second slat, each slat having a first foot and a second foot lying in a foot plane, each slat further having a length and each slat comprising a unitary rigid member extending from a first foot to form a first running member, said first running member comprising: a first side wall extending from said first foot in a direction substantially perpendicular to said foot plane, a top segment formed by bending said unitary rigid member at a substantially right angle to said first side wall so as to be substantially parallel to said foot plane, and a second side wall formed by bending said unitary rigid member back towards said foot plane at a substantially right angle; bending said unitary member at a substantially right angle from said second side wall and extending further away from said first and second side walls so as to form a bottom segment substantially coplanar with said foot plane; forming said unitary rigid member so as to include at least one additional running member extending from said bottom segment, wherein said at least one additional running member has a first side wall, a top segment, and a second side wall, and wherein said at least one additional running member first side wall extends from said bottom segment in a direction substantially perpendicular to said foot plane and substantially parallel with said first running member first side wall; and providing said at least one additional running member bottom member with a second foot integrally formed therewith, such that said second foot of said first slat can engage said first foot of said second slat so as to permit relative rotation of each of said first and second slats about an axis parallel to the side walls.
 12. The method of claim 11 wherein said top segments of said first runner member and said at least one additional runner member are wider than said bottom segment.
 13. The method of claim 11 wherein said first and second side walls of said first runner member and said at least one additional runner member each have a height H, wherein said top segments of said first runner member and said at least one additional runner member each have a width W, and wherein said height H is greater than said width W.
 14. The method of claim 11 wherein said first and second side walls of said first runner member and said at least one additional runner member each have a thickness T, and wherein said thickness T tapers from a wide point nearest said top segment to a narrower point at a bottom of said side wall members.
 15. The method of claim 11 wherein said first foot member extends substantially perpendicularly from said first side wall member in both directions.
 16. The method of claim 11 wherein said second foot member extends substantially perpendicularly from said at least one additional runner member second side wall in a single direction.
 17. The method of claim 11 wherein said second foot member terminates in a curved back segment forming an inverted T-shaped receptacle connector member.
 18. The method of claim 17 wherein said T-shape receptacle connector member is formed by a pair of curved wall members integrally formed with said at least one additional runner member, said curved wall members each having an upper end tip which extends towards the opposing curved wall member upper end tip.
 19. The method of claim 11 further including the step of providing a U-channel connector for cooperatively engaging at least one running member from said first slat and at least one running member from said second slat so as to securely join said first and second slats in end-to-end relation.
 20. The method of claim 11 further including the step of providing a third slat secured in side-by-side relation to at least one of said first or said second slat, said third slat having a plurality of running members which cooperatively engage at least one running member of said first slat or said second slat.
 21. A flooring member, comprising: a slat having a first foot and a second foot lying in a foot plane, said slat further having a length and further comprising a unitary rigid member extending from a first foot to form a first running member first side wall, being bent at an approximately right angle to said first running member first side wall and extending from said first running member first side wall to form a first running member top segment, being bent at an approximately right angle back towards said foot plane so as to form a first running member second side wall, being bent at an approximately right angle and extending further away from said first running member first side wall so as to form a bottom segment substantially coplanar with said foot plane, said first running member first side wall, top segment, first running member second side wall and bottom segment forming a first running member, said unitary rigid member extending at least one additional running member, wherein said at least one additional running member has a first side wall, a top member, a second side wall and a bottom member, and wherein said at least one additional running member first side wall extends from said first running member bottom segment in a direction substantially perpendicular to said foot plane and substantially parallel with said first running member first side wall, said at least one additional running member bottom member having a second foot integrally formed therewith.
 22. The flooring member of claim 21 wherein said slat has a length and wherein said walls, top members and bottom members extend the length of said slat. 